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At least 127 records · Page 7

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DOE OSTI2026

Nondestructive Evaluation of Carbon Fiber Reinforced Polymers

The American Society of Mechanical Engineers Boiler and Pressure Vessel Code requires repair and replacement of safety-related piping materials to meet the original Construction Code; however, no construction criteria currently exist for carbon fiber reinforced polymer (CFRP) materials in the nuclear industry. Although nondestructive examination (NDE) techniques for cast and wrought ferritic and austenitic steels are well established, licensees are increasingly deploying novel materials such as CFRP for which assessment of the use of NDE is required, as the inspectability of such materials and the influence of manufacturing processes on inspectability remain insufficiently understood. To address these gaps, Pacific Northwest National Laboratory (PNNL) evaluated the fabrication of several CFRP repair mockups and the effectiveness of NDE methods to support regulatory review of CFRP repairs in nuclear power plant applications. Representative flat-plate mockups containing realistic fabrication defects were manufactured and inspected using manual and automated tap testing, dynamic response spectroscopy (DRS), and ultrasonic testing (UT). The study identified significant fabrication variability, particularly in controlling defect size and epoxy thickness, which strongly influenced defect detectability by NDE methods. Tap testing was effective for shallow defects in thin epoxy configurations but unreliable for thicker repairs and deeper flaws. DRS demonstrated higher sensitivity to dry spots but produced unconfirmed indications for thicker plates, requiring further validation. Conventional UT, particularly at 1.0 MHz, showed the strongest overall capability for detecting a range of defects, although performance degraded with increasing repair thickness and complexity. The results highlight the need to better define critical defect sizes, develop reliable mockup fabrication methods, and validate NDE methods needed to support CFRP repairs.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Development of an Optimal Variable-Pitch Controller for Floating Axial-Flow Marine Hydrokinetic Turbines: Preprint

This article discusses the development of an optimal variable-pitch controller for floating, axial-flow marine turbines. Recently, OpenFAST, an open-source wind turbine modeling tool, has been extended to model marine turbines. A controller is necessary to simulate marine turbines for different load cases using OpenFAST, which greatly impacts the performance of the energy system. Previous studies have designed controllers using a linearized model of the marine turbine, which can be timeconsuming and require the expertise of a control engineer. In this study, we use an automated approach that uses generic models of the marine turbine to identify the controller gains, which can expedite the process of designing a controller. Using an optimizer to identify the control system parameters can additionally improve the controller's performance. The optimal controller tuned using such an approach results in a 20% reduction in the towerbase damage equivalent loading and better tracking of the rated generator speed and power.

closed-loop control↗

DOE OSTI2025

Mixed Reality Training and Workspace Integration

Mixed reality technology is being used across Idaho National Laboratory (INL) to enhance training and workforce development. Projects involving mixed reality such as lockout/tagout , the Industrial Control System Laboratory , and a Department of Defense microreactor demonstration have benefited from these innovative approaches. Several key concerns exist with integrating this new technology, including ease of use, ease of setup, and maintenance through the lifecycle. These aspects need to be properly addressed to ensure that this technology remains attractive and useful to operations teams as well as engineers and researchers at INL. Primarily, this requires buy-in from information technology management, designing software/hardware-agnostic tools, and reducing friction with technology integration. To be successful, regular operational use of this new and unfamiliar technology will require straightforward user interfaces, simple setup processes, and feature-rich experiences that reduce the time needed to benefit from the technology. INL is improving its toolset to allow for a streamlined deployment and use of mixed reality technologies that are directly available to researchers and engineers.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Comparison of a Full-Scale and a 1:10 Scale Low-Speed Two-Stroke Marine Engine Using Computational Fluid Dynamics

International marine shipping is a growing component of international trade; a vast majority of all the world’s goods are being transported on large ocean-going vessels. The International Maritime Organization (IMO) introduced the Energy Efficiency Design Index in 2013, a regulatory framework of associated metrics for reducing emissions of CO 2 per tonne-mile from shipping by approximately 10% each decade. Therefore, decarbonizing the maritime sector requires the development of new fuel sources. Because of the extremely large physical size of the internal combustion engines present in shipping vessels, experimental iterative development of the engine and fuel system is cost-prohibitive. Thus, the ability to perform combustion system development in a scaled platform that can be more easily operated and modeled computationally is of interest. To that end, scaling relationships are needed to translate the results from a smaller engine to a larger counterpart. Scaling studies to date have been restricted to low scaling ratios, four-stroke light-duty engines, and under-resolved computational fluid dynamic simulations that likely do not accurately capture the physics of scaling. In this work, computational models of a 1:10 scale and a full-scale two-stroke crosshead low-speed marine engine were created and validated against experiments obtained in a real 1:10 scale engine installed at Oak Ridge National Laboratory. Further, due to the large size of the full-scale engine, the model required large high-performance computing resources to be evaluated. The availability of high-performance computing resources at the Department of Energy’s Leadership Computing Facilities is an enabler of the current work. The results of the small- and large-scale engine simulations were compared to analyze the effectiveness of the appropriate scaling laws under these extreme scaling ratio conditions.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Sierra Space Technology Collaboration-Advanced Manufacturing of Thermal Protection System Tiles for Space Plane Atmospheric Reentry

Thermal protection systems (TPS) constitute a major material, engineering, and manufacturing challenge for space access. Atmospheric re-entry generates very high heats and requires advanced materials to withstand such conditions. Combining the required materials and integrating them into the vehicle is a major engineering undertaking that often must use creative designs to accommodate the selected materials and systems. Likewise, the manufacture of TPS is costly and challenging; it requires a combination of materials in a range of complex and unique shapes with specialized process conditions. Compounding these challenges, for harsh re-entry profiles or on high heat flux regions of the vehicle, even state of the art TPS is effectively single use and thereby creating a strong economic incentive to improve the TPS materials, integration, and manufacture. This work focuses on the use of ceramic modifications to TPS materials thereby allowing multi flight capability.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Advanced Manufacturing of Thermal Protection System Tiles for Space Plane Atmospheric Reentry

36 MATERIALS SCIENCE↗

DOE OSTI2026

Integrated System Planning: Emerging Software Requirements in the Power Industry

Power system planning software remains fragmented across organizational boundaries, with specialized tools for capacity expansion, production cost modeling, power flow, and dynamic analysis operating on incompatible data models and assumptions. This article argues that the fragmentation is not merely a technical problem but a predictable consequence of Conway's law: software architectures mirror the departmental structures within which they are developed. Regulatory milestones like Federal Energy Regulatory Commission (FERC) Order 888 formalized these divisions, but the roots trace back to the distinct engineering disciplines-mechanical, chemical, and electrical-that staffed generation and transmission planning departments in vertically integrated utilities. As the industry moves toward integrated system planning (ISP) that coordinates generation, transmission, and distribution investment decisions, the software ecosystem must evolve accordingly. We identify five categories of software requirements to enable this transition: coherent data inputs decoupled from individual applications, unified and extensible data schemas, modular component representations that support multiple abstraction levels, lifecycle management of planning datasets, and well-defined application programming interface (API) contracts that separate data exchange from algorithmic control. We examine how these requirements interact with three common workflow patterns-serial gate clearing, sequential multiapplication, and convergence oriented-and discuss the interface design principles each demands. We then outline a vision for platform-based planning architectures where specialized analytical services compose through standardized interfaces and where artificial intelligence (AI)/machine learning (ML) tools augment decision support within a disciplined software infrastructure. The practices proposed here offer a path from today's siloed tool collections toward collaborative planning ecosystems capable of handling the complexity of modern power system transformation.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Future Circular Collider Feasibility Study Report

Volume 3 of the FCC Feasibility Report presents studies related to civil engineering, the development of a project implementation scenario, and environmental and sustainability aspects. The report details the iterative improvements made to the civil engineering concepts since 2018, taking into account subsurface conditions, accelerator and experiment requirements, and territorial considerations. It outlines a technically feasible and economically viable civil engineering configuration that serves as the baseline for detailed subsurface investigations, construction design, cost estimation, and project implementation planning. Additionally, the report highlights ongoing subsurface investigations in key areas to support the development of an improved 3D subsurface model of the region. The report describes the development of the project scenario based on the ‘avoid-reduce-compensate’ iterative optimisation approach. The reference scenario balances optimal physics performance with territorial compatibility, implementation risks, and costs. Environmental field investigations covering almost 600 hectares of terrain—including numerous urban, economic, social, and technical aspects—confirmed the project’s technical feasibility and contributed to the preparation of essential input documents for the formal project authorisation phase. The summary also highlights the initiation of public dialogue as part of the authorisation process. The results of a comprehensive socio-economic impact assessment, which included significant environmental effects, are presented. Even under the most conservative and stringent conditions, a positive benefit-cost ratio for the FCC-ee is obtained. Finally, the report provides a summary of the studies conducted to document the current state of the environment.

Benedikt, M. [European Organization for Nuclear Re↗

DOE OSTI2025

FY24 LDRD Annual Report PDF

The Laboratory Directed Research and Development (LDRD) Program at Lawrence Livermore National Laboratory (LLNL) is the Lab's most significant resource for supporting internally directed research and development. It provides investments in cutting-edge science, technology, and engineering. This program expands the frontiers of knowledge, creates capabilities required by our evolving mission needs, and attracts and retains the world's most talented scientists and engineers. In this annual report, we describe the LDRD investment portfolio, provide information to demonstrate the program's value and impact to LLNL's science, technology and engineering capabilities, and showcase LDRD accomplishments across the Lab's mission space.

42 ENGINEERING↗

DOE OSTI2025

Sample glue layer investigation and mitigation for laser induced prompt impulse experiments

Understanding longer timescale material reactions under dynamic stress loading is critical for applications in materials engineering, shock physics, and planetary science. Prompt impulse experiments generate lower pressures since the ablator—the material first removed by the laser—is thicker and farther from the diagnostic plane, capturing aggregate material responses from the initial shock wave, rarefaction waves, and later time effects. This complexity demands thorough material characterization and simulation support. Since traditional sample construction is specific to supported shock experiments, designing prompt impulse experiments requires reconsideration around target design and sample engineering. Here, we present sample preparation techniques, experimental investigations, and theoretical simulations to investigate glue layer impacts, aiming to standardize samples for consistent data at lower laser fluences. We find that glue layers <30 μm have a minimal impact on peak velocity and pulse shape. The peak velocity scales linearly with glue layer thickness until a glue layer of 75 μm. For glue layers >75 μm, the peak velocity no longer scales with thickness; however, the pulse shape continues to degrade as described by simulations.

Lasers↗

DOE OSTI2025

Resource assessment of ocean thermal energy conversion in Puerto Rico and U.S. Virgin Islands

Island communities often struggle to establish and maintain traditional electric grids and are therefore heavily reliant on costly imported fossil fuels. In the case of Puerto Rico, these challenges are enhanced by extreme weather and other natural hazards that threaten the local electricity generation and transmission infrastructure. Ocean thermal energy conversion (OTEC) could play an important role in establishing a more resilient electrical grid in the region. Here, in this study, a detailed analysis is conducted to characterize the ocean thermal resource and power potential of OTEC in Puerto Rico based on a 14-year dataset of modeled ocean temperature. The assessment considers seasonal and interannual variability in the region's thermal resource and examines the operational limitations associated with minimal thermal gradients required to run a typical OTEC heat engine. Notably, the local thermal resource is found to be sensitive to El Niño-Southern Oscillation (ENSO) climate patterns, with La Niña conditions linked to greater OTEC power availability. Seven areas of opportunity are identified based on their resource potential and proximity to existing electrical distribution lines, including two that could benefit the nearby U.S. Virgin Islands. The greatest OTEC power potential is observed to the south of the main island of Puerto Rico in the Caribbean Sea with an estimated capacity of 138 MW for a plant pumping cold water from a depth of 1,000 m, or the equivalent amount of electricity required to power 219,000 households.

OTEC↗

DOE OSTI2025

Assessment of flamelet/progress variable methods for supersonic combustion

Tabulated chemistry models, including the flamelet/progress variable approach, have been successfully used for a variety of turbulent flame simulations. The progress variable describes the progress of reactions in a system and parameterizes a lookup table of thermochemical variables. This approach reduces the cost of simulations, transporting only one scalar (progress variable) instead of the many species mass fractions required for detailed chemistry. Originally developed for low Mach number flame simulations, recent works have focused on extensions of this approach to compressible flames, supersonic combustion, and detonations, with applications such as scramjet combustors and rotating detonation engines. Unlike low Mach simulations, compressible flow simulations require solving the energy transport equation, which is coupled to the equation of state. This leads to additional modeling challenges regarding the thermodynamics and its impact on the chemistry. The validity of modeling assumptions, for example the relationship between energy and temperature, also varies with the combustion regime. The present work provides a detailed assessment of the existing strategies for chemistry tabulation for compressible/supersonic combustion, including detonations. A priori analysis indicates that approximations which are reasonable for weakly compressible flames may break down for shock-induced combustion. Furthermore, the analysis identifies specific assumptions and approximations that do not hold for detonations, emphasizing that care must be taken when applying tabulated chemistry models outside their intended combustion regimes.

Detonations↗

DOE OSTI2024

Advanced fuel fusion, phase space engineering, and structure-preserving geometric algorithms

Non-thermal advanced fuel fusion trades the requirement of a large amount of recirculating tritium in the system for that of large recirculating power. Phase space engineering technologies utilizing externally injected electromagnetic fields can be applied to meet the challenge of maintaining non-thermal particle distributions at a reasonable cost. The physical processes of the phase space engineering are studied from a theoretical and algorithmic perspective. It is emphasized that the operational space of phase space engineering is limited by the underpinning symplectic dynamics of charged particles. The phase space incompressibility according to the Liouville theorem is just one of many constraints, and Gromov's non-squeezing theorem determines the minimum footprint of the charged particles on every conjugate phase space plane. In this sense and level of sophistication, the mathematical abstraction of phase space engineering is symplectic topology. To simulate the processes of phase space engineering, such as the Maxwell demon and electromagnetic energy extraction, and to accurately calculate the minimum footprints of charged particles, recently developed structure-preserving geometric algorithms can be used. The family of algorithms conserves exactly, on discretized spacetime, symplecticity and thus incompressibility, non-squeezability, and symplectic capacities. The algorithms apply to the dynamics of charged particles under the influence of external electromagnetic fields as well as the charged particle–electromagnetic field system governed by the Vlasov–Maxwell equations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Development of a micro-combined heat and power powered by an opposed-piston engine in building applications

Residential homes and light commercial buildings usually require substantial heat and electricity simultaneously. A combined heat and power system enables more efficient and environmentally friendly energy usage than that achieved when heat and electricity are produced in separate processes. However, due to financial and space constraints, residential and light commercial buildings often limit the use of traditional large-scale industrial equipment. Here we develop a micro–combined heat and power system powered by an opposed-piston engine to simultaneously generate electricity and provide heat to residential homes or light commercial buildings. The developed prototype attains the maximum AC electrical efficiency of 35.2%. The electrical efficiency breaks the typical upper boundary of 30% for micro–combined heat and power systems using small internal combustion engines (i.e., <10 kW). Moreover, the developed prototype enables maximum combined electrical and thermal efficiencies greater than 93%. The prototype is optimally designed for natural gas but can also run renewable biogas and hydrogen, supporting the transition from current conventional fossil fuels to zero carbon emissions in the future. The analysis of the unit’s decarbonization and cost-saving potential indicate that, except for specific locations, the developed prototype might excel in achieving decarbonization and cost savings primarily in US northern and middle climate zones.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

A miniaturized feedstocks-to-fuels pipeline for screening the efficiency of deconstruction and microbial conversion of lignocellulosic biomass

Sustainably grown biomass is a promising alternative to produce fuels and chemicals and reduce the dependency on fossil energy sources. However, the efficient conversion of lignocellulosic biomass into biofuels and bioproducts often requires extensive testing of components and reaction conditions used in the pretreatment, saccharification, and bioconversion steps. This restriction can result in a significant and unwieldy number of combinations of biomass types, solvents, microbial strains, and operational parameters that need to be characterized, turning these efforts into a daunting and time-consuming task. Here we developed a high-throughput feedstocks-to-fuels screening platform to address these challenges. The result is a miniaturized semi-automated platform that leverages the capabilities of a solid handling robot, a liquid handling robot, analytical instruments, and a centralized data repository, adapted to operate as an ionic-liquid-based biomass conversion pipeline. The pipeline was tested by using sorghum as feedstock, the biocompatible ionic liquid cholinium phosphate as pretreatment solvent, a “one-pot” process configuration that does not require ionic liquid removal after pretreatment, and an engineered strain of the yeast Rhodosporidium toruloides that produces the jet-fuel precursor bisabolene as a conversion microbe. By the simultaneous processing of 48 samples, we show that this configuration and reaction conditions result in sugar yields (~70%) and bisabolene titers (~1500 mg/L) that are comparable to the efficiencies observed at larger scales but require only a fraction of the time. We expect that this Feedstocks-to-Fuels pipeline will become an effective tool to screen thousands of bioenergy crop and feedstock samples and assist process optimization efforts and the development of predictive deconstruction approaches.

09 BIOMASS FUELS↗

DOE OSTI2025

Encoding hierarchical 3D architecture through inverse design of programmable bonds

The ability to fabricate materials and devices at small scales by design has resulted in tremendous technological progress. However, the need for engineered three-dimensional (3D) nanoscale materials requires new strategies for organizing nanocomponents. Here we demonstrate an inverse design approach for the assembly of nanoparticles into hierarchically ordered 3D organizations using DNA voxels with directional, addressable bonds. By identifying intrinsic symmetries in repeating mesoscale structural motifs, we prescribe a set of voxels, termed a mesovoxel, that are assembled into target 3D crystals. The relationship between different degrees of encoded information used for voxel bonds and the fidelity of assembly is investigated using experimental and computational methods. We apply this assembly strategy to create periodic 3D nanoparticle ordered organizations, including structures with low-dimensional elements, helical motifs, a nanoscale analogue of a face-centred perovskite crystal and a distributed Bragg reflector based on a crystal with plasmonic and photonic length-scale regimes.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Energy and physical resource impacts of quantum computing merit greater attention

Quantum computing research and development is growing worldwide; yet the energy and physical resource demands of future quantum-accelerated data centres are unknown. Planning for quantum computing requires strong collaboration between research communities across engineering, physics, environmental sciences, economics, policy, and energy systems and scenario modelling.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Waste to worth: a circular solution through lignin engineering

The inefficient management of industrial waste threatens environmental sustainability, requiring scalable resource recovery solutions. To address these challenges, we propose a novel and sustainable in-situ one-step strategy for the simultaneous recovery and functionalization of lignin from industrial black liquor, using a sustainable organic acid system assisted by choline chloride. The functionalized lignin adsorbent material (FLAM) exhibited superior adsorption performance, effectively treating animal feedlot wastewater to recover ammonia. The ammonia enriched FLAM was subsequently repurposed as a slow-release fertilizer, enhancing plant growth and demonstrating a closed-loop pathway for waste valorization and nutrient recycling. Methylene blue was used as a model cationic compound to simulate the adsorption behavior and interactions. FLAM achieved a high adsorption capacity of 725.98 mg/g across a broad pH range, significantly outperforming commercial kraft lignin. This sustainable approach advances circular economy principles by integrating remediation and resource recovery, offering a scalable, eco-friendly solution for environmental applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗